Automatic lead making apparatus

ABSTRACT

An apparatus that withdraws a predetermined length of electrical wire from a supply, cuts the predetermined length and places an electrical connector on at least one end of the length of wire is disclosed. The apparatus includes a movably mounted guide that positions wire from a supply of wire to a work location; a cutter for cutting a predetermined length of wire as the wire is supported by a gripper device; a movable carriage that holds a connector and brings the connector into position for attachment to the wire, and at the same time the movable guide is displaced away from the path of the movable carriage to permit the carriage to bring the connector into position for attachment to a wire as it is supported by the gripper device; and a releasing mechanism for separating a cut and predetermined length of wire from the gripping device.

BACKGROUND OF THE DISCLOSURE

I. Field of the Invention

The present invention relates generally to an apparatus for use in themanufacture of an electrical lead, and more particularly, to anapparatus that severs a predetermined length of wire from a supply andinstalls an electrical connector on at least one end of the length ofwire, both operations occurring at the same work location in theapparatus.

II. Description of the Prior Art

It is a conventional practice in the electrical wire lead manufacturingindustry to secure electrical connectors to lengths of wire. In fact,many different kinds of machines have been employed for this purpose.Generally, in known machines the desired length of wire is first pulledhorizontally, cut and then supported at both ends in the machine.Thereafter, at separately spaced apart work locations, electricalconnectors are secured to each end of the length of wire. Severalproblems arise with this type of system. First, when the electrical wireis pulled horizontally to the desired length, it must be supported atboth ends to be able to secure the connectors thereto. The problemarises in this connection when long lengths of wire are required.Obviously, the length of wire is somewhat restricted by the length ofthe machine. To overcome this problem and allow for longer wire lengths,in many manufacturing processes, the mid-section of the length of wirehas been pushed away from the machine by, for example, a cam device.However, this operation tends to bend the wire and distort it. Thus, themachine generally requires an additional device and process step whichstraightens the bent wire. Second, the efficiency of a machine of thistype is certainly lowered when there are spaced apart work locationssince this requires the operator to constantly move from one worklocation to the other. Third, an additional problem arises when it isdesired to manufacture an electrical lead formed of a plurality of wiresfed horizontally at the same time in that there is a constant problem inkeeping the wires separate and in alignment. This problem becomesparticularly acute when it is desired to manufacture long electricalleads.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to overcome many ofthe disadvantages of the wire lead making machines as described above,and to provide a novel apparatus for use in the manufacture ofelectrical wire leads which allows for a considerable increase inproduction efficiency and which provides significant practicaladvantages over known machines and techniques.

It is a further object of this invention to provide an apparatus formanufacturing electrical wire leads which cuts a predetermined length ofwire from a wire supply and installs an electrical connector on at leastone end of the length of wire, both operations occurring at the samework location.

It is another object of this invention to provide an apparatus that canform electrical wire leads of indefinite lengths without bending ordistorting the wire.

It is yet another object of this invention to provide an apparatus thatcan manufacture electrical wire leads formed of a plurality of spacedapart wires and keep the wires properly aligned during the manufacturingoperations.

It is still a further object of this invention to provide an apparatusfor manufacturing electrical wire leads which can be fully automated.

The foregoing objects and others are accomplished in accordance with thepresent invention by providing a machine for withdrawing apre-determined length of electrical wire from a supply, severing saidpre-determined length from said supply, and installing an electricalconnector on at least one end of said length the machine comprising:feed means for advancing a predetermined length of wire axially in agiven direction; guide means having an entry for receiving wire from thefeed means, and an exit for positioning wire at a work location; grippermeans spaced from the exit of the guide means along the given directionof motion of a wire, for gripping a portion of wire which has exitedfrom the guide means; cutter means movable along a path transverse tothe given direction of motion of a wire intermediate the exit of theguide means and the gripper means for severing a wire which has exitedfrom the guide means; connector carrying means movable along a pathtransverse to the given direction of motion of a wire, the path beingpositioned intermediate the exit of the guide means and the grippermeans, for advancing a connector into position for an attachment to awire which has exited from the guide means; the guide means beingmovable mounted relative the path of the connector carrying means sothat the exit of the guide means may be selectively displaced away fromthe path of the connector carrying means to permit carrying a connectorinto position for attachment to a wire gripped in the gripper means; andrelease means for separating a severed, pre-determined length of wirefrom the gripper means.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention as well as other objects andfurther features thereof, reference is made to the following detaileddisclosure of this invention taken in conjunction with the accompanyingdrawings wherein:

FIG. 1 is a fragmentary perspective view of an apparatus formanufacturing electrical wire leads in accordance with the preferredfeatures of the present invention;

FIG. 2 is a partial top plan view of a movable carriage assembly for usein the apparatus of the present invention;

FIG. 3 is a top plan view of a mechanism for driving the toolingpositioned on the carriage assembly illustrated in FIG. 2;

FIGS. 4A and 4B are top plan views, partly in section of an assemblytool used for securing an electrical connector to a wire, in open andclosed positions;

FIG. 5 is a side plan view of an embodiment of a locking mechanism forlocking the carriage assembly illustrated in FIG. 2, in place; and

FIGS. 6A, 6B, 6C, 6D, and 6E are schematic views of an apparatus formanufacturing electrical wire leads in accordance with the preferredfeatures of the present invention illustrating the primary process stepsinvolved during the operation of the apparatus.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and particularly to FIG. 1 thereof, thereis shown an embodiment of an electric wire lead making machine 10 inaccordance with the features of the present invention. As illustratedwires 11 are fed to the machine from a plurality of wire supply reels12. Although the drawings illustrate a machine that manufactureselectrical wire leads from a plurality of wires, i.e. six wires, it isto be understood that it is within the scope of the present inventionthat lead making machine 10 can manufacture electric wire leads that areformed (a) of only one wire, (b) of a plurality of wires (two, three,four, etc.) as illustrated in the drawings, or (c) of ribbon cable that,like a single wire, can be fed to the machine from only one supply reel.If ribbon cable is used, it would be apparent to one skilled in the artthe type of minor modifications that can be made to machine 10 toprocess this kind of cable into electric leads, e.g. a cutting mechanismwould be required to blank out a portion of the web between theconductors in the cable. Wires 11 are fed to a wire guide 13 thatincludes a pair of wire feed rollers 14 which are actuated by acontroller for feeding a pre-set specific length of wire down throughthe machine. Guide 13 includes a series of spaced apart openings 15 forreceiving wires 11 from wire supply reels 12, and for exiting andpositioning the wires to pivotable wire guide 16. The pivotable wireguide includes a plurality of spaced apart openings 17 which provide ameans for an entry for receiving wire, and an exit for positioning thewire at an area that will be referred to as the work location 18.Pivotable wire guide 16 is movably mounted relative to the path of anelectrical connector carrying means in the form of movable carriageassembly 19 so that exit portion 16a of guide 16 can be selectivelydisplaced away from the path of the movable carriage assembly to permitassembly 19 to carry a connector into position in work location 18 andattach a connector to wires 11 as the wires are secured in wire gripper20. Located directly beneath pivotable wire guide 16 is work location 18where various operations are performed, and the electric wire lead ismanufactured. Located directly below work location 18 along thedirection of motion of wires 11 and spaced from pivotable wire guide 16,is a gripper 20 for gripping a portion of wires 11 which have exitedfrom guide 16. The gripper is preferably in the form of a split wireguide formed of a plurality of finger-like elements (not shown) which(a) completely open to release a severed and finished electrical wirelead from the machine, (b) partially close to form a plurality ofopenings betwen the finger-like elements for the purpose of keepingwires 11 straight and preventing the wires from crossing over each otheras the wires are guided down through the machine, and (c) completelyclose to hold wires 11 in position as they are cut to a predeterminedlength. Traversing the downward path of wires 11, intermediate the exitportion 16a of pivotable wire guide 16 and gripper 20, is a motor-drivenmovable (slidable) carriage assembly 19. The carriage assembly includesas a part thereof the various assembly tools necessary for manufacturingthe electric wire leads, and transports each of these tools to worklocation 18 at the proper sequence during operation of machine 10 in amanner as explained in greater detail hereinbelow. As shown in theembodiment illustrated in FIG. 1 carriage assembly 19 includes a pair ofcutting blades 21 for severing wires 11 which have exited from wireguide 16, and two assembly tools 22 and 23. One of the assembly tools 23is for securing a connector to the leading end of wires 11 and the othertool 22 is for securing a connector to the trailing end of a determinedlength of wires 11. Although in the specific embodiment illustrated inFIG. 1, the cutting blades 21 travel with carriage assembly 19 so theyare moved laterally away from work location 18 when another process isperformed by machine 10, it is within the scope of the present inventionthat the cutting blades be mechanically secured to the frame of machine10 and be withdrawn from the work location after cutting wires 11 by ameans other than the movable carriage assembly 19.

In FIG. 2 and FIG. 3 there is shown in more detail an embodiment of amovable carriage assembly in accordance with the present invention. Asshown in FIG. 2 carriage assembly 19 includes a frame member 30 to whichis secured bearing supports 31 which allow carriage assembly 19 to beslidably mounted on two substantially parallel rails 40 (see FIG. 3)mounted within the machine frame. Secured to frame member 30 is acutting tool 32, in a first position on the carriage assembly,preferably in the form of a pair of cutting blades 21 (FIG. 1), a firstassembly tool 33 in the second position for securing an electricalconnector to the trailing end of an electrical lead, and a secondassembly tool 34 in the third position on the carriage assembly forsecuring an electrical connector to the leading end of the electricallead. Although the specific embodiment of the present invention that isdescribed herein illustrates an electrical lead making apparatus havinga movable carriage assembly 19 with three tools thereon for performingcertain operations in manufacturing a completed electrical lead, it isto be understood that it is within the scope of the present inventionthat the carriage assembly be used for supporting other tools that couldperform other types of operations on the electrical leads. Located onframe member 30, and properly aligned with cutting tool 32 and assemblytools 33 and 34, are a plurality of openings 35 and 35A which permitdriving pins to be inserted therein and activate each of these tools inthe manner as more fully described hereinbelow.

FIG. 3 shows the means by which each of cutting tool 32 and assemblytools 33 and 34 operate. Specifically, the mechanism for operating thesethree tools include a power air cylinder 41 that is activated by anelectrical air valve (not shown) which is controlled by a switch (notshown) that in turn can be activated by an operator or automatically.Secured to, and operated by power air cylinder 41 is an air cylinderpiston rod 42 that is connected to a bar element 43. Bar element 43 isconnected at one end thereof to driving pin 44 which moves in an inwarddirection through any of openings 35 on frame 30 to thereby activate onepart of either cutting tool 32 or assembly tools 33 or 34. The oppositeend of bar element 43 is secured to one end of push rod 45 that is inturn secured to a pivoting linkage 46 that pivots about pin 47. Pivotinglinkage 46 has connected to it a second driving pin 48 which moves in aninward direction through any of openings 35A at the same time drivingpin 44 moves in through any of the corresponding openings 35 to therebysimultaneously operate the second part of the cutting tool or either ofthe assembly tools.

FIGS. 4A and 4B shows in detail the two parts of an assembly tool 50, inboth an open (FIG. 4A) and closed (FIG. 4B) position, which is securedto movable carriage assembly 19 and used to place an electricalconnector on both the leading and trailing ends of the electrical leadthat is being manufactured.Specifically, there is shown an assembly toolcomprising a first portion 51 that includes a connector nest area 52into which a connector is placed either by an operator or automatically,and which connector is secured in place within nest area 52 by connectorfinger clamps 53. A cam mechanism 54 is provided to allow finger clamps53 to open. There is also illustrated an ejector mechanism 55 activatedby a driving pin (pins 44 and 47 of FIG. 3) in the manner as describedhereinabove, an ejector release key 56, and an ejector return spring 57which enables the ejector mechanism to return to an open position afterthe driving pins have withdrawn from the assembly tool. The second part58 of assembly tool 50 includes a plurality of wire inserters 59 whichallow for the proper positioning of the wires within the assembly toolso that the wires can be secured within an electrical connector whenassembly tool 50 is activated and closed, as illustrated in FIG. 4B,

FIG. 5 shows in detail a locking mechanism 60 which can be used forlocking the movable carriage assembly in position during and until aparticular operation is completed, i.e. cutting of the wires by thecutting tools or attachments of the leading or trailing end connector tothe wires by the assembly tools. The power air cylinder 41 illustratedin FIG. 3 is connected by suitable mechanical linkage to a pressureswitch (not shown). As air cylinder 41 is being pressurized, whichoccurs when either the cutting operation or the operation involving theattachment of either of the connectors are completed, at somepre-determined pressure, a pressure switch (not shown) is activated andthis in turn electrically energizes solenoid 61 which then pulls in onpiston 62. This causes lock 63 to pivot about pin 64 and remove itselffrom any of the lock openings (not shown) that are located at eachstation within frame member 30 where there is a cutting tool or assemblytool. As the movable carriage assembly is motor driven to its nextposition, the pressure air cylinder 41 is reduced to a point such thatwhen the next operational position is reached, lock 63 pivots and againlocks the carriage assembly in place.

Referring now to FIGS. 6A through 6E there is illustrated the salientprocess steps that are involved during the operation of an electricalwire lead making apparatus in accordance with the features of theinvention. At the start position for the manufacture of an electricalwire lead (See FIG. 6A) wires 70 (substantially parallel wires arelocated behind the wire shown in the drawings) extend beyond the exit ofpivotable wire guide 71 a sufficient distance to allow for securing aleading electrical connector 72 thereto. With the movable carriageassembly locked in place such that assembly tool 73 with preloadedleading electrical connector 72 being thereby properly positioned at thework location 74 a switch is activated either by an operator orautomatically which activates a power air cylinder in the manner asdescribed hereinabove to cause assembly tool 73 to move inward, secureleading connector 72 to wires 70, and then retract. Thereafter, (seeFIG. 6B) by either the press of a button by an operator or by anautomatic mode, feed rollers 75 feed a preset length of wires 70 downthrough the machine. The feeding of a preset amount of wire isaccomplished by inputting the required length of wire desired into anelectronic controller, e.g. a Superior Electric Preset Indexer--Model#SP 155A-1230, and having the controller control the operation of adrive motor, e.g. a Superior Electric SLO-SXN Stepping Motor, Model#M112-FJ326 which in turn drives rollers 75 and controls the length ofthe wires fed by these rollers. When feed rollers 75 are activated(note--the movable carriage assembly is still in a locked position), andafter about 11/2 inches of wire have been fed, the jaws of split wireguide gripper 76 partially close to form a guide through which the wirescan be guided and remain straight during the wire feeding operation. Itis important to keep the wires straight so that the wires are in aproper position for cutting, and also so they do not cross over eachother and bend. The purpose of initially feeding about 11/2 inches ofwire prior to allowing the jaws of gripper 76 to close is to allowleading connector 72 to clear the area where the jaws close. The wiresare then fed by rollers 75 to the required length. Thereafter, themovable carriage assembly is unlocked, transports the cutting tool(cutting blades) 77 to the work location 74, and is then locked intoposition (see FIG. 6C). At this time during the operation, the twoassembly tools which hold the leading and trailing connectors are loadedwith connectors by an operator or automatically. With the jaws ofgripper 76 now completely closing on wires 70 to secure the wires inplace, cutting blades 77 move in, cut the wires and retract. Withgripper 76 still completely closed on wires 70, the movable carriageassembly unlocks, transports the assembly tool having trailing connector78 therein to work location 74, and locks into position (see FIG. 6D).During this time, pivoting wire guide 71 pivots out of the work locationas shown to allow trailing connector 78 to be brought into position atthe work location, and be secured to wires 70 as the wires are firmlygripped by the jaws of gripper 76. A camming device (not shown)activated by the position of the movable carriage assembly, pivotspivoting wire guide 71 into and out of its position within the worklocation. The trailing connector is then secured to the wires. At thispoint, electrical wire lead 80 is complete, and the jaws of gripper 76fully open (see FIG. 6E) to permit the completed lead to fall away fromthe machine into a collection bin where the completed leads are stored.The opening and closing of the jaws of gripper 76 is controlled by anair cylinder (not shown) that is actuated by a microswitch that is inturn actuated by the movable carriage assembly. At this time, themovable carriage assembly unlocks, moves the assembly tool carrying aleading connector 72 to work location 74 and locks into position (seeFIG. 6A), and pivoting wire guide 71 pivots back to its originalposition.

The apparatus of this invention has been described above with regard toan operator initiating several of the operations, and also with regardto the machine operating automatically. In the totally automatic mode,the apparatus in accordance with the present invention would operate intimed sequence during the repetitive cycles of operation as describedabove. It is to be understood that coordination of all the operations ofthe apparatus in the totally automatic mode would be carried out insequence by suitable drive mechanisms and control means for such drivemechanisms. Such drive mechanisms and control means are of conventionalknown construction, and their use in the apparatus of this invention forthe totally automatic mode would be well within the knowledge of onehaving ordinary skill in the art, and therefore, are not disclosedherein.

While this invention has been described in conjunction with a specificembodiment thereof, it is evident that many alternatives, modificationsand variations will be apparent to those skilled in the art.Accordingly, the present invention is intended to embrace all suchalternatives, modifications and variations and fall within the spiritand scope of the appended claims.

What is claimed is:
 1. A method for manufacturing an electrical wire lead comprising the steps of:securing a first electrical connector to the leading end portion of at least one electrical wire at a work location which the leading end portion is being held by displaceable guide means; feeding a pre-determined length of said wire axially in a given direction, said guide means guiding said wire as it is being fed; gripping a portion of said wire; cutting said wire at said work location; displacing the guide means by pivoting it away from said work location before securing a second electrical connector to the trailing end portion of said wire; and securing a second electrical connector to the trailing end portion of said wire at said work location.
 2. An apparatus for withdrawing a pre-determined length of electrical wire from a supply, severing said pre-determined length from said supply, and installing an electrical connector on at least one end of said length, comprising:feed means mounted on support means for advancing a pre-determined length of wire axially in a given direction; guide means mounted on said support means having an entry for receiving wire from said feed means, and an exit for positioning wire at a work location; gripper means mounted on said support means and spaced from the exit of said guide means along the given direction of motion of a wire, for gripping a portion of wire which has exited from said guide means; cutter means positioned on connector carrying means and movable along a path transverse to said direction of motion of a wire intermediate said exit of said guide means and said gripper means for severing a wire which has exited from said guide means; said connector carrying means movably mounted on said support means and movable along a path transverse to said given direction of motion of a wire, said path being positioned intermediate said exit of said guide means and said gripper means, for advancing a connector into position for an attachment to a wire which has exited from said guide means; said guide means being movable mounted relative the path of said connector carrying means so that the exit of said guide means may be selectively and pivotably displaced away from the path of said connector carrying means to permit carrying a connector into position for attachment to a wire gripped in said gripper means; and release means mounted on said connector carrying means for separating a severed, pre-determined length of wire from said gripper means.
 3. An apparatus according to claim 1 wherein said feed means comprises a pair of cooperating feed rollers.
 4. An apparatus according to claim 3 wherein the length of wire fed by said rollers is controlled by a pre-set control mechanism.
 5. An apparatus according to claim 1 wherein said gripper means comprises a pair of cooperating jaws with a plurality of finger-like elements that provide a series of openings to allow for wire to pass when the jaws are in a partially closed position.
 6. An apparatus according to claim 1 wherein said connector carrying means has positioned thereon said cutter means, a first assembly tool for attaching a connector to the leading end of said wire, and a second assembly tool for attaching a connector to the trailing end of said wire.
 7. An apparatus according to claim 1 further comprising locking means mounted on said connector carrying means for securing different regions of said connector carrying means along said path of travel thereof at said work location.
 8. An apparatus according to claim 7 wherein said connector carrying means includes said cutter means positioned in a first region thereof, a first assembly tool for attaching a connector to the leading end of said wire positioned in a second region of said carrying means, and a second assembly tool for attaching a connector to the trailing end of said wire positioned in a third region of said carrying means.
 9. An apparatus according to claim 1 wherein said feed means advances a pre-determined length of a plurality of discrete electrical wires axially in a given direction.
 10. An apparatus according to claim 1 wherein said feed means advances a pre-determined length of a plurality of electrical wires in side-by-side relation axially in a given direction.
 11. An apparatus according to claim 1 wherein said feed means advances a pre-determined length of a plurality of electrical wires joined together in side-by-side relation axially in a given direction. 